TECHNOLOGIES
& TECHNIQUES
to mix colors, whereas with digital printing, this is
part of the pre-printing process. Quality standard is
more easily achieved. Work is transferred away from
machinery to prepress process.
Riley: Digital stands alone from a workflow perspec-
tive. You can pull files from the network, but it’s meant
to be run offline. Technically, you can automate some
functions, but most customers don’t do that.
Q: What advantages can digital technology bring to a
flexo printer when it comes to simplifying present day
challenges and assisting in meeting customer expec-
tations/demands?
Gilbert: Less expensive custom labels with faster
turnaround.
Frost: Digital reduces the number of process steps and
increases response time tremendously. All activities
associated with plates (preparation, fabrication, order-
ing, storing, cleaning etc.) are eliminated. Proofing can
be done on the press itself, so all activities in relation to
variations between the proofing device and the press
itself can be eliminated. Turnaround time and repeat-
ability are very important competitive parameters and
the advantage is strongly on the digital technologies.
Another benefit of digital is the ability to produce exactly
the number of labels required by the customer—no
more and no less. Overage may be source of profit for
the label printer, but it is a nuisance to the customer.
When you order 100,000 labels, that is what you want
delivered and what you want to pay for. Digital can do
that and eventually orders will go to the printers that
guarantee to deliver exactly what is ordered.
Q: Can you outline, in detail, what you believe to be the
best, step-by-step approach to introducing a digital
press and digital technology to a flexo operation?
Riley: At this point, the question is not about what is
digital, but rather when should we move to it. There
are a lot of changes. With CMYK, we can make 40 to
45 percent of Pantone colors. When we talk about la-
bel houses, our conversations are about color match-
ing and cost per label. When you start talking about
no plates and no cleanup, you can determine the cost
based on a proof print, this is music to their ears.
Frost: There is not a universal approach which would
work for everyone—but if the flexo operation is consid-
ering making its first investment in digital technology
I think they might find it beneficial to try and answer
some of the following questions:
1. What kind of new business opportunities might be
available to us if we were able to cost effectively
fulfill smaller orders than we do today?
2. What kind of cost improvement would we see
if we took our current jobs of less than 100,000
labels and produced them on a digital press?
3. How would our business improve if we are able
to dramatically reduce the time from order to
delivery?
Gilbert: You have to understand the business case,
technology and the benefits. Build up a certain know
how at the operator level. If someone intends to inte-
grate a digital press, perhaps they should reconsider
their complete workflow in order to optimize setup
times and time to market.
Q: What considerations are entailed in the installation
process, as compared to a traditional flexo press? Is it
simply “plug and play”?
Gilbert: If the preparation work is well done, then it is
just a plug-and-play process, but only if the operator
fully understands how to use a digital press.
Riley: Again, you are talking about something that is very
user friendly. Most manufacturers offer training. Our cus-
tomers tend to get the product, set it up and attempt to
run jobs before doing training. It’s pretty straightforward.
Some solutions ship exactly as you see them. There are
finishing solutions that roll out of the crate looking like
they do in a brochure. There is a learning curve, particu-
larly on the finishing side, but we’ve had people who are
ready to go within hours of delivery.
Frost: Digital reduces the number of process steps and
increases response time tremendously. All activities
Photo courtesy Durst Canada.
46
FLEXO
JANUARY
2011 www.flexography.org